Work piece

ABSTRACT

A work piece according to the prior art has caulking tabs with which it is difficult to control a caulking process due to tolerances.  
     A work piece ( 1 ) according to the invention has caulking tabs ( 3 ) that are connected to each other by means of a bridge piece ( 14 ). As a result, the caulking tabs ( 3 ) are lengthened, thus permitting better control of the caulking process because the caulking tabs ( 3 ) overlap a component ( 9 ) better.

PRIOR ART

[0001] The invention is based on a work piece as generically defined by the preamble to claim 1.

[0002] In the manufacture of sheet metal parts, e.g. for pole housings of electric machines, particularly of small-power electric motors, when the sheet metal is punched, two opposing caulking tabs are produced, which in the final assembly of the pole housing, produce a connection between the pole housing and a component, e.g. a transmission housing, by being radially caulked against the transmission housing.

[0003] A minimal punching width between the caulking tabs, which among other things, limits a length of the caulking tabs, depends on the sheet metal thickness. The thicker the sheet metal, the greater the minimum producible punching width. The shorter the caulking tab to be bent, the smaller the overlap between the caulking tab and the component.

[0004] The smaller a radial caulking stroke required to caulk the caulking tabs, the greater the sensitivity to component tolerances of the pole housing or the component, which makes the caulking process difficult to control.

ADVANTAGES OF THE INVENTION

[0005] The work piece according to the invention, with the characterizing features of claim 1, has the advantage over the prior art of improving the controllability of the caulking process in a simple way.

[0006] A length of the caulking tabs is increased by half the minimum punching width, which allows a greater sheet metal thickness to be used for the lamination bundle. The use of the pole housing as a magnetic yoke produces an improved magnetic yoke. In addition, a greater sheet metal thickness produces greater axial holding forces between the pole housing and the component. Furthermore, the lengthening of the caulking tabs results in a greater overlap on the transmission housing, as a result of which the connection of the sheet metal and the components is less sensitive to tolerances of the lamination bundle or of the component since less of a caulking stroke is required.

[0007] Advantageous modifications and improvements of the work piece disclosed in claim 1 are possible by means of the measures taken in the dependent claims.

[0008] It is advantageous if a bridge piece between the caulking tabs functions as a desired breaking point since this advantageously produces a tapering of the caulking tabs at their free ends and then advantageously functions as an assembly bevel, together with the bevel advantageously provided on the component.

[0009] The work piece is advantageously comprised of a sheet metal or a sheet metal laminate.

[0010] The work piece can advantageously be a pole housing that is then connected to a transmission housing of an electric machine.

DRAWINGS

[0011] An exemplary embodiment of the invention is shown in simplified fashion in the drawings and will be explained in detail in the subsequent description.

[0012]FIG. 1a shows a work piece according to the prior art,

[0013]FIG. 1b shows a work piece according to the prior art that is caulked to a component,

[0014]FIG. 2 shows a work piece according to the invention,

[0015]FIG. 3a shows a work piece according to the invention that is caulked to a component,

[0016]FIG. 3b shows a view of FIG. 3a.

DESCRIPTION OF THE EXEMPLARY EMBODIMENT

[0017]FIG. 1a shows a work piece 1′ according to the prior art. The work piece 1′ is comprised of a plastically deformable material, e.g. a metal. The work piece 1′ can in particular be comprised of a sheet metal or a sheet metal laminate. For example, an opening 7 is first punched out of the work piece 1′. The cross section of the opening 7 can be of any shape; in this exemplary embodiment, it is rectangular. In a subsequent production step or at the same time as the opening 7 is being produced, the opening 7 is opened out toward the edge 8 of the work piece 1′ in the form of a passage 6. A minimal punching width 5 is required for this passage 6. In the process of this, two caulking tabs 3 are produced on the work piece 1′, which border the opening 7 on both sides of the passage 6 on the side oriented toward the edge 8. These caulking tabs 3 can be bent, for example perpendicular to the plane of the drawing.

[0018] The minimal punching width 5 between the caulking tabs 3, which defines the length of these caulking tabs 3, depends on the sheet metal thickness. The thicker the sheet metal, the greater the minimal punching width resulting from the punching die.

[0019]FIG. 1b shows a work piece 1′ according to the prior art that rests against a component 9 and is attached to it. In the region in which the caulking tabs 3 of the work piece 1′ are disposed, the component 9 has a groove 10 with side walls 12 that are inclined toward each other so that the caulking tabs can be bent inward toward the side wills 12, into the groove 10 of the component, and can be caulked there, for example. A particular caulking stroke 11 is required to accomplish this. The more powerful the caulking and therefore the attachment of the work piece 1′ to the component 9 is intended to be, the further the caulking tabs 3 must be bent into the groove. The shorter the caulking tab 3 to be bent, the greater the caulking stroke that is required.

[0020]FIG. 2 shows a work piece 1 according to the invention. In the work piece 1, the caulking tabs 3 are connected to each other by means of a bridge piece 14. The bridge piece 14, however, has a smaller cross section than the caulking tabs 3 and therefore functions as a desired breaking point. The bridge piece 14 is produced, for example, by scoring the sheet metal part. During the bending of the caulking tabs 3, a more powerful force is required at the beginning because the bridge piece 14 has to be pulled apart. As the bending occurs, the material at the desired breaking point of the bridge piece 14 is stretched thinner. With further deformation, the bridge piece 14 breaks and in the same way as in the prior art, the caulking tabs 3 are bent into a groove 10 of the component 9, toward the side walls 12, and caulked there. The caulking tabs 3 are each longer than in the prior art. The stretched-thin breaking point at the free end 22 of the caulking tab 3, with the taper 20 (FIG. 3b), functions as an assembly bevel.

[0021]FIG. 3a shows a work piece 1 according to the invention that rests against a component 9 and is caulked to it. The caulking tabs 3 have been elongated by means of the bridge piece 14 so that a shorter caulking stroke 11 is required in order to produce an overlap with the component 9 comparable to the prior art.

[0022]FIG. 3b shows a top view of the work piece 1 and the component 9 in the direction B in FIG. 3a. The component 9 against which the work piece 1 according to the invention rests can be seen in the background. At their free ends 22, the caulking tabs 3 each have a taper 20 that is produced when the bridge piece 14 is stretched thin. At the back wall of the groove 10, the component 9 has, for example, a bevel 17, which is aligned perpendicular to the caulking/bending direction and whose highest part is in the vicinity of the free end 22 of the bent caulking tab 3 so that when the caulking tabs 3 are caulked into the groove 10, a caulking to the component 9 occurs due to the bevel 17. The taper 20 on the caulking tabs 3 permits a favorable transition at the beginning of the caulking process when the caulking tabs 3 are being caulked onto the bevel 17. 

1. A work piece that has two caulking tabs and is comprised of a plastically deformable material, characterized in that the caulking tabs (3) are connected to each other by means of a bridge piece (14), wherein the bridge piece (3) has a smaller cross section than the caulking tabs (3).
 2. The work piece according to claim 1, characterized in that the bridge piece (14) can be broken, that the caulking tabs (3) can be bent, and that the caulking tabs (3) can be caulked to a component (9).
 3. The work piece according to claim 1, characterized in that the bridge piece (14) constitutes a desired breaking point when the caulking tabs (3) are bent.
 4. The work piece according to claim 1, characterized in that the work piece (1) is comprised of a sheet metal or a sheet metal laminate.
 5. The work piece according to claim 1 or 4, characterized in that the work piece (1) is a pole housing of an electric machine.
 6. The work piece according to claim 1, characterized in that the work piece (1) rests against a component (9), that the component (9) has a groove (10) into which the caulking tabs (3) are bent, and that the groove (10) has a bevel (17) against which the caulking tabs (3) are slid.
 7. The work piece according to claim 1, characterized in that the free end (22) of the caulking tab (3) has a taper (20) that is partially comprised of the bridge piece (14) when the bridge piece (14) is no longer connecting the caulking tabs (3). 